Tubular pile steam curing intelligent temperature control system and matched curing method

Abstract

The invention belongs to the technical field of tubular pile curing, and provides a tubular pile steam curing intelligent temperature control system and a matched curing method, the method comprises the following four stages: a pre-curing stage: setting temperature and humidity, introducing 30-40 DEG C steam and monitoring the temperature difference between the surface and the center of a tubular pile to prevent the surface of the tubular pile from losing water too early; a foundation is laid for subsequent hydration reaction; in the heating stage, the heating rate is graded and controlled according to the pipe pile diameter, the regional temperature difference in the kiln is intelligently maintained to be smaller than or equal to 2 DEG C, the heating rate is dynamically adjusted according to the pipe pile shrinkage deformation, and pipe pile cracking is avoided; the steam amount is dynamically adjusted in the constant-temperature stage, a strength monitoring model is combined to ensure that the pipe pile is fully hydrated, the process is finished after the strength reaches 70-80% of the design strength, and the strength development of the pipe pile is guaranteed; in the cooling stage, the waste heat recovery module is started, the rotating speed of a waste heat recovery fan is intelligently adjusted in the process, waste heat is recovered to heat cold water of a water storage tank, energy is saved, the pipe pile curing quality is improved, energy consumption is reduced, and the process is controllable.

Description

Technical Field

[0001] This invention belongs to the field of pipe pile maintenance technology, and specifically relates to an intelligent temperature control system for pipe pile steam maintenance and a supporting maintenance method. Background Technology

[0002] Pipe piles are hollow, columnar precast components with a circular cross-section, mainly made of concrete (such as prestressed high-strength concrete or ordinary concrete) or steel. They are driven into the ground through methods such as driving or static pressure, serving as the core load-bearing components of a building's foundation. Their core function is to transfer and bear the vertical loads (such as the building's self-weight and the pressure from the superstructure) and horizontal loads (such as seismic forces and wind forces) of the building, transferring the loads to more stable soil or rock layers underground. At the same time, they can enhance the foundation's resistance to deformation (such as reducing settlement and resisting earthquake liquefaction).

[0003] However, traditional steam curing of pipe piles often adopts the conventional mode of "fixed heating-constant temperature-cooling", which has the following problems: low temperature control accuracy. Traditional curing relies on manual adjustment of steam valves. The temperature difference between different areas in the curing kiln, such as the upper and lower layers, and the kiln head and kiln tail, can reach 5-8℃, resulting in excessive temperature difference between the inside and outside of the pipe pile, which can easily cause cracks and affect the structural strength; serious energy waste. The steam supply adopts the "full load continuous output" mode and is not dynamically adjusted according to the hydration reaction process of the pipe pile. The steam loss rate is high, and the waste heat is not recovered during the cooling stage, which increases the additional energy consumption.

[0004] Therefore, an intelligent temperature control system for steam curing of pipe piles and a supporting curing method are proposed to solve the above problems. Summary of the Invention

[0005] To address the problems in the background art, this invention proposes an intelligent temperature control system for steam curing of pipe piles and a supporting curing method.

[0006] To achieve the above objectives, the present invention adopts the following technical solution:

[0007] Firstly, this disclosure proposes a supporting maintenance method for an intelligent temperature control system for steam curing of pipe piles, including:

[0008] S1, 1-2h pre-curing stage: Send the cast-in-place pipe pile into the curing kiln and close the kiln door. Start the intelligent control module to set the kiln temperature to 30-40℃ and humidity to ≥80%. Introduce steam at 30-40℃ and monitor the surface and center temperature of the pipe pile to ensure that the temperature difference is ≤3℃ and prevent premature water loss from the surface of the pipe pile.

[0009] S2, 3-4h heating stage: Pipe piles with Φ600mm or larger are gradually heated to 80-90℃ at a rate of 5-6℃ / h, and pipe piles with Φ600mm or smaller are heated to a rate of 7-8℃ / h. During heating, the intelligent control module maintains the temperature difference in the kiln ≤2℃ through the zoned electric regulating valve. If the displacement sensor detects that the shrinkage deformation of the pipe pile is >2mm, the heating rate is automatically reduced by 0.5-1℃ / h.

[0010] S3, 6-8h constant temperature stage: After the kiln temperature reaches the set value, the intelligent control module dynamically adjusts the steam volume according to the center temperature of the pipe pile to maintain the center temperature at 80-85℃, while keeping the kiln humidity ≥90% and the steam pressure 0.4-0.6MPa. The strength of the pipe pile is estimated through the strength monitoring model. This stage ends when the strength reaches 70%-80% of the design strength.

[0011] S4, 4-5h cooling stage: Start the waste heat recovery module, open the kiln return air vent and waste heat exchanger, and reduce the kiln temperature to 20-25℃ at a rate of 3-5℃ / h; during the cooling process, the intelligent control module adjusts the speed of the waste heat recovery fan according to the kiln temperature to recover waste heat to heat the cold water in the water storage tank. After the kiln temperature drops to 20-25℃, shut down all equipment and remove the pipe piles to complete the curing.

[0012] Preferably, during the pre-curing stage, the cast-in-place pipe piles are placed into an independent area of ​​the curing kiln. After the kiln door is closed, the intelligent control module is activated, setting the kiln temperature to 30-40℃ and the humidity to ≥80%. The steam supply and control module introduces steam at 30-40℃ into the kiln, and the monitoring sensor module collects the surface temperature T of the pipe piles in real time. 表 With center temperature T 内 To ensure that the temperature difference meets the requirements .

[0013] Preferably, the heating stage is divided into stages according to the diameter of the pipe pile, and satisfies the formula: During the heating process, the intelligent control module maintains the temperature difference between different areas inside the kiln through the zoned temperature control unit. Meanwhile, the displacement monitoring unit monitors the shrinkage deformation of the pipe pile. L, if If L>2mm, then the heating rate decreases by [amount missing]. V satisfies .

[0014] Preferably, the intelligent control module for the constant temperature stage controls the temperature at the center of the pipe pile. Dynamically adjust the steam quantity when When the temperature is below 80℃, increase the steam supply by 5-10%; when When the temperature is above 85℃, reduce the steam supply or turn on a small amount of exhaust air; during the constant temperature period, the humidity inside the kiln is ≥90% and the steam pressure is stable at 0.4-0.6MPa.

[0015] Preferably, during the cooling stage, the waste heat recovery module is activated to gradually reduce the kiln temperature to 20-25℃ at a rate of 3-5℃ / h; during the cooling process, the heat exchange capacity of the waste heat recovery module satisfies the formula ,in Let m be the specific heat capacity of water, and m be the amount of water involved in the heat exchange. , which is the change in water temperature. The temperature of the water after heat exchange. The temperature of the water before heat exchange is the temperature of the water. The recovered heat is used to heat the cold water in the storage tank.

[0016] Secondly, this disclosure proposes an intelligent temperature control system for steam curing of pipe piles, comprising:

[0017] The curing kiln module is used to provide a closed, insulated, and zoned curing space for pipe piles;

[0018] The steam supply and control module is used to dynamically adjust the pressure and flow rate of steam.

[0019] The monitoring and sensing module can collect multi-dimensional parameters of the pipe piles and the maintenance environment in real time;

[0020] The intelligent control module, based on the built-in "hydration and thermal coupling temperature control model", coordinates with other modules to perform temperature control, abnormal alarms, and remote control.

[0021] The waste heat recovery module is used to recover and recycle the waste heat during the cooling process.

[0022] The data storage and traceability module is used to store data throughout the entire maintenance process, supporting quality traceability and process optimization.

[0023] Preferably, the curing kiln module adopts a fully enclosed insulated kiln body with a thick rock wool and polyurethane composite insulation layer. The kiln body is divided into 3-5 independent curing areas, each of which can accommodate 2-4 layers of pipe piles. Each independent curing area is equipped with an independent steam distribution pipe and return air inlet. The diameter of the steam distribution pipe is 50-80mm, and multiple Φ3-5mm steam outlet holes are opened on the pipe wall. The steam supply and control module is also equipped with a pressure safety valve on the main steam pipeline, which automatically releases pressure when the pressure of the main pipeline exceeds 0.8MPa.

[0024] Preferably, the steam supply and control module includes a steam generation unit, a zone temperature control unit, and a pressure stabilizing unit;

[0025] The steam generating unit is a fully automatic gas-fired steam generator, equipped with an automatic water level control device;

[0026] Each zone temperature control unit corresponds one-to-one with an independent maintenance area. Each zone temperature control unit includes one set of electric regulating valves, a flow meter, and a pressure sensor. The electric regulating valves are electrically connected to the intelligent control module, and their steam supply regulation satisfies the following formula: Where k is an adjustment coefficient, with a value ranging from 0.8 to 1.2. For the real-time temperature of the monitored area, Set the temperature for this area. The rated steam supply for the area, with each adjustment ranging from 5% to 10%;

[0027] The pressure stabilizing unit is a pressure stabilizing valve installed on the main steam pipeline.

[0028] Preferably, the monitoring sensing module includes a temperature monitoring unit, a humidity monitoring unit, and a displacement monitoring unit;

[0029] The temperature monitoring unit is equipped with ≥5 PT100 platinum resistance temperature sensors in each independent maintenance area. These sensors are installed on the surface of the pipe pile at 1 / 3 of its length at both ends, at the center of the pipe pile pre-embedded during pouring, and in the air inside the kiln at a height of 1.5m above the kiln floor.

[0030] The humidity monitoring unit is a humidity sensor installed inside the kiln to monitor the humidity of the curing environment in real time.

[0031] The displacement monitoring unit consists of at least one displacement sensor installed at each of the two ends and the middle of the pipe pile to monitor the shrinkage deformation ΔL of the pipe pile. When the shrinkage deformation of the pipe pile... When the heating rate is reduced, the alarm mechanism of the intelligent control module is triggered when ΔL>3mm.

[0032] Preferably, the intelligent control module is based on a PLC controller, equipped with a touch screen human-machine interface, and has a built-in "hydration heat coupling temperature control model". This model automatically adjusts the steam supply to each area based on the strength development curve of the pipe pile and real-time monitoring data. The strength development curve of the pipe pile is obtained by fitting using a nonlinear regression method, and its expression is: ,in The intensity at time t, The final strength is given by k, which is the hydration rate constant. The waste heat recovery module includes a waste heat exchanger, a water storage tank, and a circulating water pump. The data storage and traceability module is equipped with an industrial-grade database to store data on temperature, pressure, humidity, steam consumption, equipment operating status, and pile deformation during the maintenance process in real time.

[0033] The beneficial effects of this invention are:

[0034] 1. This invention, through the partitioned structure of the curing kiln module, combined with the dynamic steam regulation capability of the steam supply and control module, and the real-time acquisition of multi-dimensional parameters of the pipe pile and the kiln environment by the monitoring and sensing module, enables the intelligent control module to accurately regulate the temperature and humidity of each curing area. This solves the problems of large temperature difference inside the kiln and uneven heating inside and outside the pipe pile in traditional curing, allowing the pipe pile to be in a uniform and stable curing environment in each stage of pre-curing, heating, constant temperature, and cooling, effectively avoiding the generation of pipe pile cracks and improving the quality of pipe pile forming.

[0035] 2. The waste heat recovery module and the steam supply module of this invention work together. The waste heat of the high-temperature wet steam recovered during the cooling stage can be used to heat the cold water in the water storage tank and supply water to the steam generator. At the same time, the intelligent control module dynamically adjusts the steam supply according to the maintenance process, abandoning the wasteful mode of "full load continuous steam supply" in traditional maintenance, realizing the efficient use of energy recycling, and reducing the overall energy consumption of pipe pile maintenance.

[0036] 3. This invention uses an intelligent control module to link the monitoring and sensing module, data storage and traceability module. During the maintenance process, parameters can be automatically monitored and equipment adjusted without frequent manual intervention. Moreover, the entire process of maintenance data is stored in real time, and can be quickly queried and traced by pipe pile number, maintenance time, etc. This solves the defects of traditional maintenance manual recording with large errors and difficulty in tracing back quality problems. It not only improves the intelligence of maintenance, but also facilitates the full life cycle management of pipe pile quality.

[0037] Other features and advantages of the invention will be set forth in the following description, and will be apparent in part from the description, or may be learned by practicing the invention. The objects and other advantages of the invention may be realized and obtained by means of the structures pointed out in the description and the drawings. Attached Figure Description

[0038] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0039] Figure 1 A flowchart of a method for a steam curing intelligent temperature control system and supporting curing method for pipe piles according to the present invention is shown;

[0040] Figure 2 The diagram shows a system framework of an intelligent temperature control system for steam curing of pipe piles and a supporting curing method according to the present invention. Detailed Implementation

[0041] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0042] Reference Figure 1 As shown, a maintenance method for a smart temperature control system for steam curing of pipe piles specifically includes the following steps:

[0043] S1, 1-2h pre-curing stage: Send the cast-in-place pipe pile into the curing kiln and close the kiln door. Start the intelligent control module to set the kiln temperature to 30-40℃ and humidity to ≥80%. Introduce steam at 30-40℃ and monitor the surface and center temperature of the pipe pile to ensure that the temperature difference is ≤3℃ and prevent premature water loss from the surface of the pipe pile.

[0044] S2, 3-4h heating stage: Pipe piles with Φ600mm or larger are gradually heated to 80-90℃ at a rate of 5-6℃ / h, and pipe piles with Φ600mm or smaller are heated to a rate of 7-8℃ / h. During heating, the intelligent control module maintains the temperature difference in the kiln ≤2℃ through the zoned electric regulating valve. If the displacement sensor detects that the shrinkage deformation of the pipe pile is >2mm, the heating rate is automatically reduced by 0.5-1℃ / h.

[0045] S3, 6-8h constant temperature stage: After the kiln temperature reaches the set value, the intelligent control module dynamically adjusts the steam volume according to the center temperature of the pipe pile to maintain the center temperature at 80-85℃, while keeping the kiln humidity ≥90% and the steam pressure 0.4-0.6MPa. The strength of the pipe pile is estimated through the strength monitoring model. This stage ends when the strength reaches 70%-80% of the design strength.

[0046] S4, 4-5h cooling stage: Start the waste heat recovery module, open the kiln return air vent and waste heat exchanger, and reduce the kiln temperature to 20-25℃ at a rate of 3-5℃ / h; during the cooling process, the intelligent control module adjusts the speed of the waste heat recovery fan according to the kiln temperature to recover waste heat to heat the cold water in the water storage tank. After the kiln temperature drops to 20-25℃, shut down all equipment and remove the pipe piles to complete the curing.

[0047] During the pre-curing stage, the cast-in-place pipe piles are placed into the independent area of ​​the curing kiln. After the kiln door is closed, the intelligent control module is activated, setting the kiln temperature to 30-40℃ and the humidity to ≥80%. The steam supply and control module introduces steam at 30-40℃ into the kiln, and the monitoring sensor module collects the surface temperature T of the pipe piles in real time. 表 With center temperature T 内 To ensure that the temperature difference meets the requirements .

[0048] Specifically, the process of placing the pipe piles into the kiln and setting the parameters is as follows: Pipe piles with a surface flatness of ≤5mm after casting (such as prestressed concrete pipe piles) are placed into an independent area of ​​the curing kiln, with a spacing of ≥100mm between piles to ensure steam circulation. After closing the kiln door, the intelligent control module is activated, and pre-curing parameters are set: kiln temperature... =30-40℃, relative humidity RH≥80%, continuous for 2 hours when ambient temperature ≤15℃, continuous for 1 hour when ambient temperature ≥25℃;

[0049] Steam supply and temperature difference control: The steam supply and control module introduces steam at 30-40℃ into the kiln, and the PT100 platinum resistance temperature sensor of the monitoring and sensing module collects the surface temperature of the pipe pile in real time. Temperature at the center of the pipe pile ,by Calculate the temperature difference between the surface and center of the pipe pile:

[0050] 1. If ≤3℃, maintain the current steam supply;

[0051] 2. If >3℃, according to the formula Adjust the steam supply, among which The adjustment coefficient ranges from 0.6 to 0.9. Rated steam supply for the maintenance area;

[0052] Steam distribution uniformity control: During the pre-curing stage, it is necessary to ensure uniform steam distribution within the area. This is controlled by the flow deviation rate of each steam outlet, using the following formula: %,in Let i be the real-time flow rate of the i-th steam outlet. The average flow rate across all steam outlets is calculated by monitoring the electromagnetic flowmeter. >5%, the intelligent control module fine-tunes the opening of the electric regulating valve to make the steam distribution more uniform.

[0053] During the heating stage, the heating rate needs to be controlled to avoid excessive temperature difference between the inside and outside of the pipe pile, which could lead to cracks, while maintaining a stable temperature difference in different areas of the kiln.

[0054] Specifically, the heating rate is controlled in stages: the intelligent control module sets the initial heating rate based on the diameter of the pipe pile, satisfying the formula: ;

[0055] Kiln zone temperature difference control: During the heating process, the intelligent control module maintains the temperature difference between different zones within the kiln through the electric regulating valves of the zone temperature control unit. ,in This is the highest temperature in the region. For the lowest temperature in the region, the adjustment amount of the electric regulating valve opening satisfies the formula: , This is an adjustment coefficient, with a value ranging from 0.8 to 1.2. For the real-time temperature of the area, Set the temperature for the area, adjusting it by 5-10% each time to avoid temperature fluctuations.

[0056] Pipe pile deformation feedback adjustment: The LVDT displacement sensor of the displacement monitoring unit monitors the shrinkage deformation of the pipe pile in real time. ,like If the deformation is greater than 2mm, adjust the heating rate according to the amount of deformation:

[0057] 1. When At that time, the heating rate decreased to 0.5. ;

[0058] 2. When When the heating rate decreases by 1 ;

[0059] 3. When Once the temperature reaches ≤2mm, resume the initial heating rate until the kiln temperature reaches the target value.

[0060] During the constant temperature stage, precise control of the center temperature, humidity, and steam pressure is required to ensure that the hydration reaction is complete and uniform.

[0061] Specifically, the center temperature is dynamically adjusted: the intelligent control module adjusts the center temperature of the pipe pile based on the data collected by the monitoring sensor module. Dynamically adjust steam volume:

[0062] 1. If If the temperature is below 80℃, increase the steam supply, and adjust the amount of steam required each time. , For the current steam supply, until Rise to 80-85℃;

[0063] 2. If the temperature exceeds 85℃, reduce the steam supply, and adjust the range as needed each time. Alternatively, open the small exhaust valve at the top of the kiln and maintain the exhaust volume at [a certain level]. The kiln body area should be adjusted to avoid excessively high temperatures that could cause the hydrated products to become loose.

[0064] Temperature, humidity, and pressure stability control: During constant temperature operation, maintain the relative humidity (RH) inside the kiln ≥ 90%, and the steam pressure 0.4-0.6 MPa. A humidity sensor monitors RH in real time. If RH < 90%, the intelligent control module increases the steam supply. A pressure sensor monitors the steam pressure, and the pressure regulating valve operates according to the formula... Maintain pressure fluctuation range to ensure temperature control accuracy.

[0065] Pipe pile strength estimation and stage completion determination: The pipe pile strength σ is estimated in real time using the temperature-strength correlation formula, the formula is as follows: , For the design strength of the pipe pile, The constant temperature time (h) is used for pipe pile calibration. , , , The value when At this point, the constant temperature phase ends.

[0066] During the cooling phase, the cooling rate needs to be controlled while recovering residual heat to achieve energy conservation and protect the quality of the pipe piles.

[0067] Specifically, cooling rate and fan speed control: Activate the waste heat recovery module, press 3-5... The rate gradually lowers the kiln temperature to room temperature, i.e., 20-25°C. The intelligent control module adjusts the temperature based on the real-time temperature inside the kiln. Adjust the speed n of the waste heat recovery fan to satisfy the formula: ,in This is a proportionality coefficient, with a value ranging from 300 to 500. ; The actual cooling rate ( ), take 500 in the initial stage of cooling 300 later ;

[0068] Waste heat recovery and heat exchange calculation: During the cooling process, 80-90% of the heat discharged from the kiln... High-temperature wet steam enters the waste heat exchanger and reacts with the 20-25°C water in the storage tank. The cold water undergoes heat exchange, and the heat exchange rate satisfies the formula: , Let m be the specific heat capacity of water, and m be the amount of water participating in heat exchange, taken as 80% of the water volume in the storage tank. The change in water temperature Controlled between 50-60 ;

[0069] Curing completion and pipe pile removal: After the kiln temperature drops to room temperature, shut down all system equipment (steam generator, circulating water pump, sensors, etc.), let it stand for 30 minutes to allow the pipe pile temperature to balance with the room temperature to avoid stress concentration caused by sudden temperature changes, and then open the kiln door to remove the pipe pile, thus completing the curing process.

[0070] Reference Figure 2 As shown, based on the same inventive concept as the above method, this disclosure also proposes an intelligent temperature control system for steam curing of pipe piles, comprising:

[0071] The curing kiln module is used to provide a closed, insulated, and zoned curing space for pipe piles;

[0072] The steam supply and control module is used to dynamically adjust the pressure and flow rate of steam.

[0073] The monitoring and sensing module can collect multi-dimensional parameters of the pipe piles and the maintenance environment in real time;

[0074] The intelligent control module, based on the built-in "hydration and thermal coupling temperature control model", coordinates with other modules to perform temperature control, abnormal alarms, and remote control.

[0075] The waste heat recovery module is used to recover and recycle the waste heat during the cooling process.

[0076] The data storage and traceability module is used to store data throughout the entire maintenance process, supporting quality traceability and process optimization.

[0077] The curing kiln module adopts a fully enclosed insulated kiln body, with the insulation layer being a composite structure of thick rock wool and polyurethane. The electrical conductivity of the rock wool is approximately [missing value]. The thermal conductivity of polyurethane is approximately The overall thermal conductivity after composite According to the heat conduction formula Where Q is the heat flow rate and A is the heat transfer area. d represents the temperature difference between the inside and outside of the kiln, and d represents the thickness of the insulation layer. The insulation effect of the insulation layer can be selected by machine to ensure that the temperature inside the kiln is minimally affected by the outside environment.

[0078] The kiln is divided into 3-5 independent curing zones. Each independent curing zone can accommodate 2-4 layers of pipe piles, enabling independent curing of pipe piles of different batches and specifications. Each independent curing zone is equipped with an independent steam distribution pipe and return air inlet. The diameter of the steam distribution pipe is 50-80mm, and multiple Φ3-5mm steam outlet holes are opened on the pipe wall to ensure uniform steam diffusion. The return air inlet is located at the end of the zone to form steam circulation.

[0079] Each area is equipped with a high-temperature resistant quartz glass observation window on its side wall to reduce heat loss during non-observation periods. The steam supply and control module also features a pressure relief valve on its main steam pipeline, which automatically releases pressure when the main pipeline pressure exceeds 0.8 MPa, with the pressure release amount meeting [the required standard]. Where C is the safety valve flow coefficient, and P is the main pipeline pressure. Atmospheric pressure This represents the density of the vapor.

[0080] The steam supply and control module dynamically adjusts the steam pressure / flow rate to provide a suitable steam environment for pipe pile maintenance. It includes a steam generation unit, a zoned temperature control unit, and a pressure stabilization unit.

[0081] Specifically, the steam generation unit is implemented as follows: a fully automatic gas-fired steam generator with a rated evaporation capacity of 0.5-1 t / h is used, equipped with an automatic water level control device. The water level in the tank is monitored by a liquid level sensor, and if the water level is lower than the threshold, the generator will control the steam generation unit. Water supply interruption, water level fluctuation ±5mm, steam generation meets requirements ,in The heat released by the combustion of gas To utilize the latent heat of water vaporization and ensure stable steam production;

[0082] Zoned temperature control units are implemented: each unit corresponds to an independent zone, and each unit includes an electric regulating valve, an electromagnetic flow meter, and a pressure sensor. The electric regulating valve is electrically connected to the intelligent control module, and the steam supply regulation meets the following requirements: k is an adjustment coefficient, taking values ​​between 0.8 and 1.2. For the real-time temperature of the area, To set the temperature, Adjust the rated steam volume for the area by 5-10% each time to avoid drastic temperature fluctuations.

[0083] Pressure stabilization unit implementation: A pressure stabilizing valve is installed on the main steam pipeline. The valve core is used to adjust and maintain stable pressure, with pressure fluctuations ≤ ±0.02MPa. The flow rates before and after the valve meet the requirements. Where K is the flow coefficient and S is the valve core opening. The pressure difference across the valve. The density of the steam is used to provide a stable steam source for each zone.

[0084] The monitoring and sensing module collects multi-dimensional parameters of the pipe pile and the environment in real time to provide data for intelligent control. It includes a temperature monitoring unit, a humidity monitoring unit, and a displacement monitoring unit.

[0085] Specifically, the temperature monitoring unit is implemented as follows: ≥5 PT100 platinum resistance temperature sensors are installed in each independent area, respectively mounted on the surface of the pipe pile at 1 / 3 of its length from both ends, to monitor... It is pre-embedded in the center of the pipe pile during pouring and monitored. Air inside the kiln at a height of 1.5m above the ground was monitored. Temperature through Calculate, where R is the real-time resistance of the PT100. The resistance at 0℃ ≈0.00385 / ℃;

[0086] Humidity monitoring unit implementation: A capacitive humidity sensor is installed inside the kiln, near the return air inlet, and monitors humidity through... ,in It is a dry air capacitor. This is the humidity capacitance coefficient, which reflects the relative humidity (RH).

[0087] Displacement monitoring unit implementation: At least one LVDT displacement sensor is installed at both ends and the middle of the pipe pile to monitor the shrinkage deformation ΔL. When the pipe pile shrinks... When the heating rate is reduced, an alarm is triggered when ΔL > 3mm, provided that the displacement and voltage meet the requirements. ,in is the displacement-to-voltage conversion coefficient, and V is the sensor output voltage.

[0088] The intelligent control module is based on a PLC controller and equipped with a touch screen. It links various modules based on the "hydration and thermal coupling temperature control model" to achieve temperature control, alarm and remote control.

[0089] Specifically, the hydration heat coupling temperature control model is implemented: the model is based on the strength-time curve of the pipe pile. ,in Let be the intensity at time t. The final strength is given by k, which is the hydration rate constant. The amount of steam is dynamically adjusted based on real-time monitoring data.

[0090] Abnormal alarm implementation: When the temperature / pressure / humidity exceeds the preset threshold or ΔL>3mm, an audible and visual alarm is triggered, and a text message is sent to the management personnel via 4G / 5G.

[0091] Remote control implementation: Supports 4G / 5G connection to cloud platform, enabling remote viewing, modification and start / stop control of maintenance parameters.

[0092] The waste heat recovery module recovers and recycles waste heat from the cooling stage, and includes a waste heat exchanger, a water storage tank, and a circulating water pump.

[0093] Specifically, the heat exchange process is implemented as follows: During the cooling stage, the 80-90℃ high-temperature wet steam in the kiln enters the plate waste heat exchanger and exchanges heat with the 20-25℃ cold water in the water storage tank.

[0094] Water recycling implementation: After heat exchange, hot water is sent to the steam generator's water supply tank, and condensate is filtered through a 50μm filter before returning to the storage tank. The water recycling rate is high, and a liquid level sensor monitors the water level in real time to ensure stable circulation.

[0095] The data storage and traceability module stores data throughout the entire process, supports quality traceability, and is equipped with an industrial-grade database.

[0096] Specifically, data storage implementation: real-time storage of surface / center / kiln temperature of the pipe pile ( ), steam pressure (P), humidity (RH), steam consumption ( Data such as equipment status and deformation (ΔL) are stored for a period of ≥3 years.

[0097] Data query and report generation implementation: Supports querying by pipe pile number ID or maintenance time t. The query logic is Date=F(ID,t), where Date is the maintenance dataset. It automatically generates maintenance reports, including quality assessment results such as temperature-time, pressure-time, parameter exceedance, deformation, and strength compliance, which facilitates traceability and process optimization.

[0098] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes the element.

[0099] Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A supporting maintenance method for the intelligent temperature control system of pipe pile steam maintenance, characterized in that, include: S1, 1-2h pre-curing stage: Send the cast-in-place pipe pile into the curing kiln and close the kiln door. Start the intelligent control module to set the kiln temperature to 30-40℃ and humidity to ≥80%. Introduce steam at 30-40℃ and monitor the surface and center temperature of the pipe pile to ensure that the temperature difference is ≤3℃ and prevent premature water loss from the surface of the pipe pile. S2, 3-4h heating stage: Pipe piles with Φ600mm or larger are gradually heated to 80-90℃ at a rate of 5-6℃ / h, and pipe piles with Φ600mm or smaller are heated to a rate of 7-8℃ / h. During heating, the intelligent control module maintains the temperature difference in the kiln ≤2℃ through the zoned electric regulating valve. If the displacement sensor detects that the shrinkage deformation of the pipe pile is >2mm, the heating rate is automatically reduced by 0.5-1℃ / h. S3, 6-8h constant temperature stage: After the kiln temperature reaches the set value, the intelligent control module dynamically adjusts the steam volume according to the center temperature of the pipe pile to maintain the center temperature at 80-85℃, while keeping the kiln humidity ≥90% and the steam pressure 0.4-0.6MPa. The strength of the pipe pile is estimated through the strength monitoring model. This stage ends when the strength reaches 70%-80% of the design strength. S4, 4-5h cooling stage: Start the waste heat recovery module, open the kiln return air vent and waste heat exchanger, and reduce the kiln temperature to 20-25℃ at a rate of 3-5℃ / h; during the cooling process, the intelligent control module adjusts the speed of the waste heat recovery fan according to the kiln temperature to recover waste heat to heat the cold water in the water storage tank. After the kiln temperature drops to 20-25℃, shut down all equipment and remove the pipe piles to complete the curing.

2. The maintenance method for a steam curing intelligent temperature control system for pipe piles according to claim 1, characterized in that: During the pre-curing stage, the cast-in-place pipe piles are placed into an independent area of ​​the curing kiln. After the kiln door is closed, the intelligent control module is activated, setting the kiln temperature to 30-40℃ and the humidity to ≥80%. The steam supply and control module introduces steam at 30-40℃ into the kiln, and the monitoring sensor module collects the surface temperature T of the pipe piles in real time. 表 With center temperature T 内 To ensure that the temperature difference meets the requirements .

3. The maintenance method for a steam curing intelligent temperature control system for pipe piles according to claim 1, characterized in that: The heating stages are divided into stages according to the diameter of the pipe pile, and satisfy the formula: During the heating process, the intelligent control module maintains the temperature difference between different areas inside the kiln through the zoned temperature control unit. Meanwhile, the displacement monitoring unit monitors the shrinkage deformation of the pipe pile. L, if If L>2mm, then the heating rate decreases by [amount missing]. V satisfies .

4. The maintenance method for a steam curing intelligent temperature control system for pipe piles according to claim 1, characterized in that: The intelligent control module for the constant temperature stage is based on the center temperature of the pipe pile. Dynamically adjust the steam quantity when When the temperature is below 80℃, increase the steam supply by 5-10%; when When the temperature is above 85℃, reduce the steam supply or turn on a small amount of exhaust air; during the constant temperature period, the humidity inside the kiln is ≥90% and the steam pressure is stable at 0.4-0.6MPa.

5. The maintenance method for a steam curing intelligent temperature control system for pipe piles according to claim 1, characterized in that: During the cooling phase, the waste heat recovery module is activated, gradually reducing the kiln temperature to 20-25℃ at a rate of 3-5℃ / h. During the cooling process, the heat exchange capacity of the waste heat recovery module satisfies the formula... ,in Let m be the specific heat capacity of water, and m be the amount of water involved in the heat exchange. , which is the change in water temperature. The temperature of the water after heat exchange. The temperature of the water before heat exchange is the temperature of the water. The recovered heat is used to heat the cold water in the storage tank.

6. An intelligent temperature control system for steam curing of pipe piles, characterized in that, include: The curing kiln module is used to provide a closed, insulated, and zoned curing space for pipe piles; The steam supply and control module is used to dynamically adjust the pressure and flow rate of steam. The monitoring and sensing module can collect multi-dimensional parameters of the pipe piles and the maintenance environment in real time; The intelligent control module, based on the built-in "hydration and thermal coupling temperature control model", coordinates with other modules to perform temperature control, abnormal alarms, and remote control. The waste heat recovery module is used to recover and recycle the waste heat during the cooling process. The data storage and traceability module is used to store data throughout the entire maintenance process, supporting quality traceability and process optimization.

7. The intelligent temperature control system for steam curing of pipe piles according to claim 6, characterized in that: The curing kiln module adopts a fully enclosed insulated kiln body with a thick rock wool and polyurethane composite insulation layer. The kiln body is divided into 3-5 independent curing areas, each of which can accommodate 2-4 layers of pipe piles. Each independent curing area is equipped with an independent steam distribution pipe and return air inlet. The diameter of the steam distribution pipe is 50-80mm, and multiple Φ3-5mm steam outlet holes are opened on the pipe wall. The steam supply and control module is also equipped with a pressure safety valve on the main steam pipeline, which automatically releases pressure when the pressure of the main pipeline exceeds 0.8MPa.

8. The intelligent temperature control system for steam curing of pipe piles according to claim 6, characterized in that, The steam supply and control module includes a steam generation unit, a zone temperature control unit, and a pressure stabilizing unit. The steam generating unit is a fully automatic gas-fired steam generator, equipped with an automatic water level control device; Each zone temperature control unit corresponds one-to-one with an independent maintenance area. Each zone temperature control unit includes one set of electric regulating valves, a flow meter, and a pressure sensor. The electric regulating valves are electrically connected to the intelligent control module, and their steam supply regulation satisfies the following formula: Where k is an adjustment coefficient, with a value ranging from 0.8 to 1.

2. For the real-time temperature of the monitored area, Set the temperature for this area. The rated steam supply for the area, with each adjustment ranging from 5% to 10%; The pressure stabilizing unit is a pressure stabilizing valve installed on the main steam pipeline.

9. The intelligent temperature control system for steam curing of pipe piles according to claim 6, characterized in that: The monitoring and sensing module includes a temperature monitoring unit, a humidity monitoring unit, and a displacement monitoring unit; The temperature monitoring unit is equipped with ≥5 PT100 platinum resistance temperature sensors in each independent maintenance area. These sensors are installed on the surface of the pipe pile at 1 / 3 of its length at both ends, at the center of the pipe pile pre-embedded during pouring, and in the air inside the kiln at a height of 1.5m above the kiln floor. The humidity monitoring unit is a humidity sensor installed inside the kiln to monitor the humidity of the curing environment in real time. The displacement monitoring unit consists of at least one displacement sensor installed at each of the two ends and the middle of the pipe pile to monitor the shrinkage deformation ΔL of the pipe pile. When the shrinkage deformation of the pipe pile... When the heating rate is reduced, the alarm mechanism of the intelligent control module is triggered when ΔL>3mm.

10. The intelligent temperature control system for steam curing of pipe piles according to claim 6, characterized in that: The intelligent control module is based on a PLC controller and equipped with a touch screen human-machine interface. It incorporates a "hydration-thermal coupling temperature control model," which automatically adjusts the steam supply to each area based on the strength development curve of the pipe piles and real-time monitoring data. The strength development curve of the pipe piles is obtained using a nonlinear regression method, and its expression is: ,in The intensity at time t, The final strength is given by k, which is the hydration rate constant. The waste heat recovery module includes a waste heat exchanger, a water storage tank, and a circulating water pump. The data storage and traceability module is equipped with an industrial-grade database to store data on temperature, pressure, humidity, steam consumption, equipment operating status, and pile deformation during the maintenance process in real time.

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